Eyeglass frames

ABSTRACT

An eyeglass frame that includes a frame body having a lens support portion, and first and second earstem portions, which extend rearwardly from first and second lateral sides of the lens support portion, respectively. The frame body includes a first member and a second member. The first and second members are partially coextensive, and each of the first and second members define a portion of an outward-facing surface of the eyeglass frame.

CLAIM OF PRIORITY

This application is a divisional of U.S. patent application Ser. No.10/737,709, filed Dec. 16, 2003, which is related to, and claimspriority from, U.S. Provisional Patent Application No. 60/434,168, filedDec. 16, 2002, each of which is incorporated in its entirety byreference herein and made a part of this specification.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to eyeglass frames and, moreparticularly, to an eyeglass frame constructed from more than onemember. The present invention also relates to a method for making suchan eyeglass frame.

2. Description of the Related Art

Eyeglass frames generally include a front portion, which supports a pairof optical lenses on opposing sides of a nose bridge. A pair of earstemstypically extend in a rearward direction from the front portion. Theearstems may be connected to the front portion through a hingearrangement to allow movement of the earstems between a folded positionand an opened positioned, relative to the front portion of the eyeglassframe. In many arrangements, each component (i.e., the front portion andearstems) of the eyeglass frame is monolithic and constructed of asingle material, such as metal or plastic. In other arrangements, aninternal strengthening member may be included. Such an arrangement isespecially common for the earstems of plastic eyeglass frames. However,such a strengthening member is usually not visible, or not prominentlyvisible, and does not form an external surface of the eyeglass frame.

SUMMARY OF THE INVENTION

One aspect of at least one of the inventions disclosed herein, includesthe realization that an eyeglass frame can be manufactured with anopaque inner and structurally supportive portion and an outertransparent or translucent and structurally supportive portion coveringthe inner portion. For example, the outer portion can be made from aclear acetate or polycarbonate material and molded over the innerportion, so as to generate a clear boundary between the inner and outerportions.

In one embodiment, the inner portion is provided with a highly-sculptedouter surface, and the outer portion is transparent or translucent,leaving the inner, highly-sculpted portion visible through the outerportion. In certain applications, this allows the highly-sculptedportion of the frame to be smaller and thus less expensive tomanufacture. The outer portion provides additional structural support tothe smaller inner portion, without completely eliminating the aestheticcontribution of the inner portion. Where the outer portion istransparent, the aesthetic contribution of the inner portion isessentially unobstructed from view. Accordingly, portions of the framecan be constructed at least partially from a desired material withouthaving to be strong enough to withstand all of the forces imparted tothe entire frame assembly.

A preferred embodiment of one of the inventions disclosed herein isdirected to an eyeglass frame comprising a frame body including a frameportion and first and second earstem portions. The frame portion definesfirst and second orbitals, each of said orbitals configured to supportan optical lens. The earstem portions are spaced from one another andextend in a rearward direction from said front portion. The frame bodycomprises a first member and a second member. The first member and thesecond member are at least partially coextensive, and each of the firstand second members define a portion of an outer surface of the framebody.

Another embodiment of at least one invention disclosed herein isdirected to an eyeglass frame comprising a frame body including a frontportion configured to support at least one optical lens, and first andsecond earstem portions. The earstem portions are spaced from oneanother and extend in a rearward direction from the front portion. Theframe body comprises a first member and a second member. The first andsecond members are at least partially coextensive and each define atleast a portion of an external surface of the frame body. The firstmember has sufficient transparency such that a surface of the secondmember is visible through said first member.

In yet another embodiment of at least one invention disclosed herein, aneyeglass frame comprises a lens support portion, and first and secondearstem portions extending rearwardly from first and second lateralsides of the lens support portion, respectively. At least one of thefirst and second earstem portions comprises a first portion and a secondportion disposed over the first portion, the first portion extendingover only about one-third of the total length of the earstem.

In an additional embodiment of at least one invention disclosed herein,an eyeglass frame comprises an orbital support portion and first andsecond earstem portions extending rearwardly from first and secondlateral side portions of the orbital support, respectively. Each earstemcomprises an inner portion formed of a first material, and an outerportion formed of a second translucent material.

In accordance with an embodiment of at least one invention disclosedherein, a method of manufacturing an eyeglass frame comprises forming aframe body. The frame body including a frame portion and first andsecond earstem portions. The frame portion defines first and secondorbitals, each of the orbitals being sized and shaped to support anoptical lens. Additionally, the frame body defines a recess. The methodalso includes forming an insert portion. The insert portion is sized andshaped to occupy the recess of the frame body. Additionally, the methodincludes positioning the insert portion into the recess such that eachof the frame body and the insert portion define a portion of an externalsurface of said eyeglass frame.

Another embodiment of at least one invention disclosed herein isdirected to a method of manufacturing an eyeglass frame comprisingforming a first lens orbital from a first material, and molding a secondmaterial around a periphery of said lens orbital.

Yet another embodiment of at least one invention disclosed herein isdirected to a method of manufacturing an eyeglass frame comprisingforming an orbital support portion of a first material. The method alsoincludes forming at least a first optical lens of the first material.Additionally, the method includes connecting a stiffening member to aperiphery of the first optical lens. Finally, the method includessupporting the stiffening member with the orbital support.

Another embodiment of at least one invention disclosed herein isdirected to a method of manufacturing an eyeglass frame comprisingforming a front portion defining at least one orbital. The method alsoincludes forming a pair of earstems, each of the earstems including arecess. An insert portion is provided within the recess, and the pair ofearstems are assembled to the front portion.

Yet another embodiment of at least one invention disclosed herein isdirected to an eyeglass frame including a frame body having a frameportion and first and second earstem portions. The frame portion definesat least one orbital configured to support an optical lens. The framebody includes a first layer and a second layer that are at leastpartially coextensive. The eyeglass frame includes means for affixingthe first layer to the second layer such that each layer defines aportion of an outer surface of the frame body.

Yet another embodiment of at least one invention disclosed herein isdirected to an eyeglass frame comprising a frame body including a frameportion and first and second earstem portions. The frame portion definesfirst and second orbitals. Each of the orbitals is configured to supportan optical lens. The earstem portions are spaced from one another andextend in a rearward direction from said front portion. The frame bodycomprises a first member and a second member. A forward-facing surfaceof the first member defines a first shape. The second member is coupledto the first member and is coextensive with a portion of theforward-facing surface of the first member such that each of the firstmember and the second member define a portion of a forward-facingsurface of the frame body. The second member defines a second shapesubstantially similar to the first shape.

Another embodiment of at least one invention disclosed herein isdirected to a method of manufacturing an eyeglass frame includingforming a first frame body member having a frame portion and first andsecond earstem portions. The frame portion defines first and secondorbitals each configured to support an optical lens. A forward-facingsurface of the first frame body member defines a first shape. The methodfurther includes forming a second frame body member defining a secondshape substantially similar to said first shape and affixing the secondframe body member to the first frame body member such that each define aportion of a forward-facing surface of the eyeglass frame.

Yet another embodiment of at least one invention disclosed herein isdirected to an eyeglass frame including a frame body defining first andsecond orbitals. Each of the first and second orbitals are configured tosupport an optical lens. The frame body includes a first member and asecond member. The first member defines a first shape and the secondmember defines a second shape substantially similar to the first shape.The eyeglass frame also includes means for affixing the second member tothe first member such that each define a portion of a forward facingsurface of the frame body.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the presentinvention are described below with reference to drawings of preferredembodiments, which are intended to illustrate, but not to limit thepresent invention. The drawings comprise the following figures:

FIG. 1 is a front and left side perspective view of an eyeglass framehaving certain features, aspects and advantages of one of the inventionsdisclosed herein.

FIG. 2 is an exploded assembly view of the eyeglass frame of FIG. 1.

FIG. 3 is cross-sectional view of the eyeglass frame of FIG. 1, takenalong the line 3-3 of FIG. 1.

FIG. 4 is an exploded assembly view of a modification of the eyeglassframe of FIG. 1.

FIG. 5 is a cross-sectional view of the eyeglass frame of FIG. 4 takenalong the line 5-5 of FIG. 4.

FIG. 6 is a flow diagram of a preferred method for constructing theeyeglass frame of FIG. 1, wherein the outer portion of the frame bodyand earstems are formed first and an insert portion of the frame bodyand earstems are formed over the outer portions.

FIG. 7 is a flow diagram of a preferred method of constructing theeyeglass frame of FIG. 1, wherein an insert portion of the frame bodyand earstems is formed first and the outer portion of the frame body andearstems are formed over the insert portions.

FIG. 8 is a flow diagram of a preferred method for constructing theeyeglass frame of FIG. 1, wherein the outer portion of the frame bodyand the earstems and the insert portion of the body and the earstems areformed separately and then assembled together.

FIG. 9 is a flow diagram of a preferred method for constructing theeyeglass frame of FIG. 4, wherein a metal insert portion of the framebody and the earstem portion are formed first and the outer portion ofthe frame body and the earstem is formed over the metal insert portion.

FIG. 10 is a flow diagram of a preferred method for constructing theeyeglass frame of FIG. 4, wherein the metal insert portion of the framebody and earstems are formed separately from the outer portion of theframe body and the earstems and the insert portion and outer portion arethen assembled together.

FIG. 11 is a front, top and left side perspective view of an alternativeembodiment of an eyeglass frame having plate-like members attached to anexternal surface of an inner frame member.

FIG. 12 is a rear, bottom and right side perspective view of theeyeglass frame of FIG. 11.

FIG. 13 is a front, top and left side perspective view of the eyeglassframe of FIG. 11 in an exploded condition illustrating the inner framemember separated from the plate-like members and ear stems.

FIG. 14 is a front elevational view of the eyeglass frame of FIG. 11.

FIG. 15 is a rear elevational view of the eyeglass frame of FIG. 11.

FIG. 16 is a left side elevational view of the eyeglass frame of FIG.11.

FIG. 17 is a right side elevational view of the eyeglass frame of FIG.11.

FIG. 18 is a top plan view of the eyeglass frame of FIG. 11.

FIG. 19 is a bottom plan view of the eyeglass frame of FIG. 11.

FIG. 20 is an enlarged view of a portion of the inner frame and a platemember that has yet to be assembled to the inner frame member. The platemember includes a pair of projection facing the inner frame member andthe inner frame member includes a corresponding pair of roughenedsurface area portions facing the projections of the plate member.

FIG. 21 is a flow diagram of a preferred method for constructing theeyeglass frame of FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1-3 illustrate an eyeglass frame 20 constructed in accordance withat least one invention disclosed herein. The eyeglass frame 20 includesa front portion 22 and a pair of earstem portions 24. The front portion22 defines a pair of openings, or orbitals 26, which are configured tosupport a pair of optical lenses 28. The front portion 22 also defines anose bridge 30 extending between the pair of orbitals 26.

The earstems 24 extend in a rearward direction from opposing lateralsides of the front portion 22. Desirably, each earstem 24 is connectedto the front portion 22 by a hinge arrangement, to be movable between afolded position and an open position relative to the front portion 22.

The hinge arrangement of each earstem 24 comprises a pair of cylindricalprotrusions 32 extending from an upper surface and a lower surface,respectively, of a forward end of the earstem 24. The protrusions 32 aresized and shaped to be received within corresponding cavities 34 of eachlateral end of the front portion 22. Thus, each earstem 24 is pivotalabout an axis defined by the pair of protrusions 32 and correspondingcavities 34. However, other assemblies can be used to pivotally mountthe earstems 24 to the front portion 22.

Although the illustrated eyeglass frame 20 includes a pair of orbitals26 supporting a pair of optical lenses 28, other arrangements arepossible wherein a single, toroidal lens is used. In such anarrangement, the orbital 26 may surround the entire lens or only aportion thereof. Furthermore, although the earstems 24 are connected tothe front portion 22 through a hinged arrangement in the illustratedeyeglass frame 20, in an alternative arrangement, the earstems 24 andfront portion may be unitarily formed, wherein the earstems 24 aresubstantially fixed relative to the front portion 22.

Preferably, each of the front portion 22 and the earstems 24 areconstructed from two distinct materials. That is, preferably the frontportion 22 includes an outer portion 36 and an inner portion 38 and eachof the earstems 24 includes an outer portion 40 and an inner portion 42.As used throughout this description, the term “outer portion” isintended to refer to the portion that defines the outwardly facingsurface of the subject component, i.e., the front portion 22 andearstems 24. Thus, “outer portion” is intended to include the portions36 and 40 defining the surface that faces outwardly away from a wearerof the eyeglass frame 20. The term “inner portion” is intended toinclude portions 38, 42 disposed inside the outer portion. In somearrangements, the inner portion also defines a portion of the outersurface of the frame 20, however, this inner portion faces inwardlytoward the wearer of the eyeglass frame 20.

The illustrated hinge arrangement, comprised of the protrusions 32 andcorresponding cavities 34, connects the outer portion 40 of the earstems24 to the outer portion 36 of the front portion 22. However, in analternative hinge arrangement, the inner portions 38, 42 of the frontportion 22 and earstems 24 may be connected to one another. Furthermore,a hinge arrangement may be provided that interconnects the front portion22 and earstems 24 through both of the outer portions 36, 40 and innerportions 38, 42.

In the illustrated eyeglass frame 20, the outer portion 36 of the frontportion 22 of the eyeglass frame 20 defines a recess 44 and the outerportion 40 of the earstems 24 defines a recess 46. The inner portions38, 42 are sized and shaped to occupy the recesses 44, 46 of the frontportion 22 and earstems 24, respectively. Thus, the outer portions 36,40 are partially coextensive with their respective inner portions 38,42.

In the illustrated eyeglass frame 20, the recesses 44, 46 are formed bya rearwardly facing surface (i.e., the surface facing the wearer of theeyeglass frame 20) of the front portion 22 and the earstems 24,respectively. However, in alternative arrangements, the inner portions38, 42 may be positioned in recesses formed on other surfaces of theeyeglass frame 20, such as forward, upper or lower surfaces.

In the illustrated arrangement, the recess 44 of the front portion 22 ofthe eyeglass frame 20 surrounds each orbital 26. Thus, the innerportions 38 also surround each orbital 26. In the illustrated eyeglassframe 20, the recesses 44 of each orbital 26 are separate from oneanother. However, in an alternative arrangement, the recesses 44, andthus the inner portions 38, of each orbital 26 may be interconnected,such as by a portion extending across the nose bridge 30, for example.

In addition, the recesses 46 of the earstems 24 desirably extend no morethan about one-third of the total length of the earstems 24. Thus, theinner portions 42 extend no more than about one-third of the length ofthe earstem 24. In certain embodiments, this construction provides anadditional advantage. For example, in an embodiment where the innerportions 42 are made from a material that has a stiffness greater thanthat of the material forming the outer portions 40, the limited lengthof the inner portions 42 allows the earstem to retain much of theflexibility of the lower-stiffness outer portion. In one embodiment, theinner portions 42 are made from a high-stiffness metal, such astitanium, and the outer portions 40 are made from polycarbonate, whichis relatively less stiff than titanium.

In other arrangements, the recess 46 and insert portion 42 may extend agreater distance along the earstems 24. Furthermore, although each ofthe front portion 22 and earstems 24 define a recess 44, 46,respectively in the illustrated eyeglass frame 20, in otherarrangements, the inserts 38, 42 may be included on only one of thefront portion 22 and the earstems 24.

With reference to FIG. 3, preferably the outer portion 36 and the innerportion 38 of the front portion 22 of the eyeglass frame 20 cooperate todefine a groove 48, which is configured to retain an optical lens 28within each orbital 26. However, in other arrangements, the groove 48may be defined entirely by the outer portion 36 or the insert portion38.

The inner portions 38, 42 may be secured within their respective recess44, 46 in any suitable manner. For example, but without limitation, theinner portions 38, 42 can be mechanically fastened to the outer portions36, 40 using techniques such as ultra-sonic or RF welding andovermolding. Alternatively, the inner portions 38, 42 may be chemicallybonded to the other portions 36, 40 using adhesives or the like.

Preferably, the outer portions 36, 40 are constructed of a materialhaving sufficient transparency such that the inserts 38, 42 are bevisible through the outer portions 36, 40. For example, the outerportions 36, 40 may be essentially transparent, wherein the inserts 38,42 are visible through the other portions 36, 40 with little or nodistortion. Alternatively, the outer portions 36, 40 may be translucent,wherein the appearance of the inserts 38, 42 is affected by the outerportions 36, 40, but not completely obfuscated.

In some arrangements, one or both of the inner portions 38, 42 can serveas structural reinforcing members. Optionally, one or both of the innerportions 38, 42 can be stiffer than the outer portions 36, 40. In otherarrangements, one or both of the inner portions 38, 42 can beconstructed from a material with a modulus of elasticity that is greaterthan that of the outer portions 36, 40. In such an arrangement, theinner portion 38 of the front portion 22 of the eyeglass frame 20 mayserve to reinforce the orbital 26 and thereby provide appropriatesupport to the optical lens 28 supported therein. For example, butwithout limitation, where the inner portion 38 is made from a metal suchas titanium, and the outer portion 36 is made from polycarbonate, suchthat the inner portion 38 has a higher overall stiffness than the outerportion 36, the inner portion 38 better protects the shape of the lens28.

To achieve a greater stiffness, the inner portions 38, 42 may be madefrom a material that is inherently stiffer than the material of theouter portions 36, 40. Alternatively, the inner portions 38, 42 may bemade from the same or similar material as the outer portions 36, 40 andmay be manipulated to achieve greater stiffness. For example, both theinsert portion 38, 42 and the outer portions 36, 40 may be constructedfrom a thermoplastic material, with the inner portions 38, 42 beingcrystallized, while the outer portions 36, 40 are amorphous. Othersuitable means for achieving greater stiffness of the inner portions 38,42 may also be used, such as altering the orientation of the material,for example.

With an eyeglass frame 20 as described above, the inner portions 38, 42may be made from a colored material, while the outer portions 36, 40 maybe transparent or translucent. Accordingly, in such an arrangement, thecolored inner portions 38, 42 are visible through the outer portions 36,40 to provide a desired color throughout a selected portion of theeyeglass frame 20.

Advantageously, such an arrangement enables flexibility in changing thecolor of the eyeglass frames being produced in a short time frame. Theillustrated arrangement also eliminates the need of stockpiling largenumbers of complete eyeglass frames in a variety of colors. For example,with a preferred method of manufacturing the eyeglass frame 20, theouter portions 36, 40 of the front portion 22 and earstems 24,respectively, may be manufactured in advance, or on a continual basis,based on predicted, long term demand. The inner portions 38, 42 may beproduced in smaller amounts, or batches, to meet immediate demand foreyeglass frames of a desired color(s), or materials.

Accordingly, the outer portions 36, 40 may be produced in quantitiessufficient to meet long term forecasts for the demand of a specificframe style, while the quantities of various colors of the innerportions 38, 42 may be changed on a frequent basis to meet immediatedemand for specific colors of the eyeglass frame. Preferred methods forconstructing the eyeglass frame 20 of FIGS. 1-3 are described in greaterdetail below with reference to FIGS. 6-8.

FIGS. 4 and 5 illustrate a modification of the eyeglass frame 20 ofFIGS. 1-3 and is generally referred to by the reference numeral 20′. Theeyeglass frame 20′ is similar to the eyeglass frame 20 of FIGS. 1-3 and,therefore, like reference numerals will be used to indicate likecomponents, except that a prime (′) is added.

The front portion 22′ of the eyeglass frame 20′ includes an innerportion 38′, which preferably is constructed from a material that isstiffer than the material of the outer portion 36′. Preferably, theinner portion 38′ is constructed from a metal, such as steel, titaniumor magnesium, for example, and the outer portion 38′ is constructed froma plastic material. The increased stiffness of the inner portion 38′provides support to, and inhibits distortion of, the optical lens 28′.In addition, the stiffer inner portion 38′ inhibits unintendeddislodgment of the optical lens 28′ from the eyeglass frame 20′.

Preferably, the inner portion 38′ is sized and is sufficiently stiffsuch that it is not distorted during insertion of the optical lens 28′into the groove 48′, unlike the procedure commonly used for inserting alens into a plastic eyeglass frame. To permit insertion of the lens 28′in to the groove 48′, the groove 48′ is wider than the thickness of thelens 28′. Accordingly, the lens 28′ may be positioned into the groove48′, without requiring the inner portion 38′ to be flexed, or distorted.

To secure the lens 28′ within the groove 48′, a retaining member, suchas a gasket 50, can be inserted into the groove 48′ behind the opticallens 28′. Desirably, the retaining member 50 is somewhat flexible and issized and shaped, along with an optical lens 28′, to occupy the entirewidth of the groove 48′. Desirably, the retaining member 50 is at leastslightly compressed when positioned within the groove 48′ such that itexerts a force on the lens 28′ to ensure that the lens 28′ is securelyheld within the groove 48′.

Although the above-described arrangement is preferred, other suitablearrangements to retain the lens 28′ to the insert 38′ may also be used.For example, a typical rim lock arrangement may be used wherein a cut ismade through the insert portion 38′, in a radial direction, to permitthe insert member 38′ to flex in order to allow the optical lens 28′ tobe inserted into the groove 48′. The two sides of the insert portion 38′on opposing sides of the cut may be secured to one another with afastener, such as a screw, for example. Other arrangements apparent toone of skilled in the art are also possible.

Eyeglass frames constructed entirely from a metal material aresubstantially more expensive than eyeglass frames constructed from aplastic material. A portion of the additional expense is a result of thedifference in the cost of the raw material. An additional cause for thegreater expense of metal eyeglass frames compared to plastic frame isthe greater difficulty in forming a metal material into the oftenintricate shape of an eyeglass frame. For example, the hinge manufactureof the connection between the earstems and the front portion of theeyeglass frame is substantially more difficult for a metal frame.

Advantageously, with the eyeglass frame 20, 20′ described above, theappearance of a metal frame may be achieved with the use of metal innerportions 38, 42, 38′, 42′ for a substantially reduced cost compared to aframe made entirely of metal. The cost savings is realized both by usingless of the more expensive metal material and by providing innerportions 38, 42, 38′, 42′ having a relatively basic shape. Therefore,forming of the metal inner portions 38, 42, 38′, 42′ is less complexthan forming an entire frame from a metal material and the more complexportions of the frame 20, 20′ (e.g., the hinge assembly) may be formedfrom plastic. Accordingly, an eyeglass frame 20, 20′ as illustrated inFIGS. 1-5 presents a distinct advantage over frames constructed entirelyof either metal or plastic materials.

With reference to FIGS. 6-10, a number of preferred methods forconstructing an eyeglass frame such as the frames 20, 20′, areillustrated. The methods are described in relation to a number ofprocess flow diagrams, which set forth preferred steps in theconstruction of an eyeglass frame. As will be apparent to one of skillin the art, not all of the steps are necessarily required to practicethe invention and, furthermore, additional steps can be performed inaddition to those illustrated.

FIG. 6 illustrates a preferred method 52 for constructing the eyeglassframe 20 of FIGS. 1-3 utilizing a process wherein the outer portions 36,40 of the front portion 22 and earstems 24, respectively, are formedinitially and the inner portions 38, 42 are formed within the recesses44, 46 of the outer portions 36, 40.

The method 52 includes a first step 54 of forming the outer portion 36of the front portion 22 of the frame 20 in a first mold. In a preferredembodiment, the outer portion 22 is formed by injection molding atranslucent or transparent, plastic material such as, for example, butwithout limitation, polycarbonate.

The formed outer portion 22 is then positioned within a second mold instep 56. In step 58, the insert portion 38 is then formed in the secondmold, wherein the recess 44 acts as a portion of the mold surface. Sucha process is referred to as “over-molding”.

The first mold and the second mold may be completely separate from oneanother or they may be separate portions of the same molding machine.For example, the outer portion 36 may be molded in the first moldaccording to step 54 and then may be stored as work-in-process materialand subjected to steps 56 and 58 at a later time. Alternatively, theouter portion 36 may be molded in a first portion of a molding machineand transferred to a second mold immediately after withdrawal from thefirst mold. That is, the outer portion 36 and the insert portion 38 maybe formed in a single process step comprising two substeps.

Similarly, the outer portions 40 of the earstems 24 are formed in afirst mold in step 60. In step 62, the outer portions 40 are transferredto a second mold and the inner portions 42 of the earstems 24 are formedin step 64 in a manner similar to that described above in relation tosteps 56 and 58.

After the front portion 22 and the earstem portions 24 have been formed,they are assembled to one another in step 66. With the hingedarrangement comprising a pair of protrusions 32 and correspondingcavities 34, as described above, the earstems 24 may be snapped intoplace. Alternatively, if the front portion 22 in the earstems 24 areconnected by a separate hinge assembly, additional process steps may berequired, as is apparent to one of skill in the art.

In step 68, the lenses 28 are assembled to the frame 20 in a knownmanner. Preferably, the lenses 28 can be snapped into place within thegroove 48 of the eyeglass frame 20, due to the flexible nature of theplastic material forming the frame 20.

With reference to FIG. 7, an alternative method for constructing aneyeglass frame, such as the eyeglass frame 20 of FIG. 1, is illustrated.In the method 70, the inner portions 38, 42 of the front portion 22 andearstems 24, are initially formed and the outer portions 36, 40 areformed over the inner portions 38, 42.

In step 72, the insert portion 38 of the front portion 22 is formed in afirst mold. In step 74, the formed insert portion 38 is positioned in asecond mold and, in step 76, the outer portion 36 is formed over theinsert portion 38 in the second mold. Preferably, the steps 72, 74, 76are substantially similar to the methods described above in relation tothe method 52 of FIG. 6. Accordingly, in method 70, the insert portion38 and outer portion 36 may be formed as a single process step or theinsert portion 38 may be formed as a separate process step as describedabove.

Similarly, in step 78, the insert portion 42 of the earstem 24 is formedin a first mold. Then, in step 80, the insert portion 42 is placedwithin a second mold and, in step 82, the outer portion 40 is formedover the insert portion 42 in the second mold.

Similar to the method 52 of FIG. 6, once the front portion 22 andearstems 24 are formed, they are assembled to one another in step 84. Instep 86, the lenses 28 are assembled to the frame 20.

With reference to FIG. 8, an alternative method 88 to construct aneyeglass frame, such as the frame 20 of FIGS. 1-3, is illustrated. Inthe illustrated method 88, the outer portions 36, 40 and the innerportions 38, 42 are formed separately from one another. Once formed, therespective inner portions 38, 42 and outer portions 36, 40 are assembledtogether. Specific steps of the preferred process 88 are described ingreater detail below.

In step 90, the outer portion 36 of the front portion 22 is formed in afirst mold. Separately, in step 92, the insert portion 38 is formed in asecond mold. Once the insert portion 38 and outer portion 36 are formed,they are assembled to one another in step 94. The outer portion 36 andinsert portion 38 may be formed from a plastic material by injectionmolding or, alternatively, may be formed from other suitable materialsor processes.

As described above in relation to FIGS. 1-3, the outer portion 36 andthe insert portion 38 may be mechanically coupled, such as with afastener member, or may be secured together by a snap-fit arrangement,for example. Additionally, or alternatively, the outer portion 36 andthe insert portion 38 may be chemically coupled to one another, such aswith adhesives or the like. Optionally, in step 96, once the outerportion 36 and the insert portion 38 are assembled, the front portion 22of the eyeglass frame 20 may be subjected to a raised temperature toinduce chemical bonding, or adhesion, between the contacting surfaces ofthe outer portion 36 and the insert portion 38.

Similarly, in step 98, the outer portion 40 of the earstem 24 is formedin a first mold. Separately, the insert portion 42 of the earstem 24 isformed in a second mold in step 100. After being formed, the outerportion 40 and the insert portion 42 of the earstem 24 are assembled instep 102, preferably in a manner similar to that described in relationto step 94. Optionally, the assembly of the outer portion 40 and theinsert portion 42 may be heated to enhance the bonding therebetween instep 104, as described in relation to step 96.

Once the front portion 22 in the earstems 24 are formed, they areassembled to one another in step 106. Once the eyeglass frame 20 isassembled in step 106, the lenses 28 are assembled to the frame 20 instep 108. These assembly steps 106, 108 preferably are substantiallysimilar to the assembly steps 66, 68 or 84, 86 described in relation toFIGS. 6 and 7.

FIG. 9 illustrates a preferred method 110 for constructing an eyeglassframe, such as the frame 20′ of FIGS. 4 and 5. In the method of FIG. 9,the inner portions 38′, 42′ are initially formed from a metal materialand the outer portions 36′, 40′ are formed over the inner portions 38′,42′.

In step 112, the insert portion 38′ of the front portion 22′ of theframe 20′ is formed from a metal material. As described above, the metalmaterial may be steel, aluminum, magnesium, titanium or other metalmaterials suitable for supporting an optical lens. The insert may beformed through any number of suitable processes, such as die casting orinvestment casting, as is appreciated by one of skilled in the art.

After the insert portion 38′ is formed, it is positioned in a first moldin step 114. In step 116, the outer portion 36′ is formed over theinsert portion 38′. Preferably, the outer portion 36′ is constructedfrom a plastic material that is injection molded (e.g., over-molded)over the insert portion 38′.

Preferably in a manner similar to that of the insert portion 38′ of thefront portion 22′ in step 112, the insert portion 42′ of the earstem 24′is formed in step 118. The formed insert portion 42′ is positionedwithin a first mold in step 120 and, in step 122, the outer portion 40′of the earstem 24′ is formed over the insert portion 42′. Preferably,the outer portion 40′ is over-molded onto the insert portion 42′ by aninjection molding process.

Once the front portion 22′ and earstems 24′ are formed, they areassembled to one another in step 124′ to create an assembled frame 20′.Once the frame 20′ has been assembled, the lenses 28′ are assembled intothe frame 20′ in step 126. The lenses 28′ may be assembled to the frame20′ using any suitable method, such as using the retaining member 50 asdescribed above in relation to FIGS. 4 and 5.

FIG. 10 illustrates an alternative method 128 for constructing aneyeglass frame, such as the eyeglass frame 20′ of FIGS. 4 and 5. In themethod 128 of FIG. 10, the lenses 28′ are assembled to form metalinserts 38′ before assembly of the insert portion 38′ to the outerportion 36′.

In step 130, a metal insert portion 38′ of the front portion 22′ of theeyeglass frame 20′ is formed by a suitable method, such as thosedescribed above in relation to step 112 of FIG. 9. In step 132, thelenses 28′ are assembled to the insert portion 38′ by a suitable methodsuch as using a retaining member 50, or using a standard split rim lock,as previously described.

The outer portion 36′ of the front portion 22′ of the eyeglass frame 20′is formed in step 134. Preferably, the outer portion 36′ is formed froma plastic material by injection molding. However, other suitable methodsand materials may also be used.

In step 136, the assembly of the insert portion 38′ and lens 28′ isassembled to the outer portion 36′ through a suitable arrangement. Forexample, the insert 38′ may be mechanically secured to the outer portion36′ through a snap-fit arrangement, mechanical fasteners or the like. Inan eyeglass frame having a pair of optical lenses, two insert portion38′ and lens 28′ assemblies are created in step 136.

In a manner similar to the metal insert portion 38′ in step 130, themetal insert 42′ of the earstem 24′ is formed in step 138. In step 140,the outer portion 40′ of the earstem 24′ is formed in a first mold and,in step 142, the metal insert portion 42′ and the outer portion 40′ areassembled to form the earstem 24′. Once the front portion 22′ and a pairof earstems 24′ have been formed, they are assembled together in step144 to create an assembled eyeglass frame, such as the frame 20′ ofFIGS. 4 and 5.

FIGS. 11 through 21 illustrate an alternative embodiment of an eyeglassframe, generally referred to by the reference numeral 150. Preferably,the eyeglass frame 150 includes inner and outer portions, morepreferably, is comprised of two distinct members of material fixedlycoupled to one another. In a preferred arrangement, the two members ofmaterial are at least partially co-extensive and each define at least aportion of a forward-facing surface of the eyeglass frame 150, as isdescribed in greater detail below.

The eyeglass frame 150 includes a front portion 152, which defines atleast one orbital, and preferably both right-side and left-side orbitals154. As in the previous embodiments, the orbitals 154 are configured tosupport an optical lens (not shown). The illustrated front portion 152includes a nose bridge 156 extending between the orbitals 154. In otherarrangements, however, the front portion 152 may be configured tosupport a single, toroidal optical lens, as described above.Accordingly, in alternative arrangements, the orbital(s) do notnecessarily entirely surround the lens, or lenses.

In the illustrated arrangement, a pair of earstems 158 extend in arearward direction from opposing, lateral sides of the front portion152. As in the previous embodiments, preferably the earstems 158 areconnected to the front portion 152 through a hinge arrangement such thatthe earstems 158 are movable from a folded position to an openedposition relative to the front portion 152, as is well known in the art.

With reference to FIGS. 11 through 13, the illustrated front portion 152includes an inner frame member 160 and a plurality of outer, plate-likemembers, including a central member 162, a right upper member 164R, aleft upper member 164L, a right lower member 166R, and a left lowermember 166L. Preferably, the plate members 162, 164 and 166 are fixedlysecured to the inner frame member 160 to form a front portion 152 thatis of an integrated structure. Although multiple plate members 162, 164and 166 are provided in the illustrated embodiment, other numbers ofplate members may also be used, including a singular plate member, forexample.

In the illustrated arrangement, the center plate member 162 and upperand lower plate members 164 and 166 are arranged to form a shape, whichis generally similar in shape to a forward-facing surface 160A of theinner frame member 160. Desirably, the plate members 162, 164, 166 coverat least a portion of the forward-facing surface 160A of the inner frame160, while permitting a portion of the forward-facing surface 160A to bevisible when the eyeglass frame 150 is viewed from the front. In theillustrated arrangement, the plates 162, 164, 166 cover substantiallythe entire forward-facing surface 160A of the inner frame member 160,with the exception of relatively small gaps 168 between the individualplates 162, 164, 166. Thus, the inner frame member 160 comprises a firstmember of material of the front portion 152 and the plate members 162,164, 166 comprise a second member of material of the front portion 152.These two members can be the same color. Alternatively, the two memberscan be different colors.

In a preferred arrangement, the center plate member 162 extends fromapproximately a central portion, of both an upper and a lower side, ofthe pair of orbitals 162 and across the nose bridge 156 of the eyeglassframe 150. The upper and lower plate members 164, 166 cooperate with thecenter plate member 162 to substantially surround the remaining portionof the respective right-side and left-side orbitals 154. Thus, the platemembers 162, 164, 166 cooperate to substantially surround each of theright and left orbitals 154. In addition, as described above, the innerframe member 160 preferably also surrounds each orbital 154 and, in apreferred arrangement, defines a pair of grooves 170 configured tosupport an optical lens (not shown).

With reference to FIG. 12, preferably, at least a portion of one or moreof the plate members 162, 164, 166 defines a frontal surface area thatis greater than the frontal surface area of a corresponding portion ofthe inner frame member 160. That is, at least a portion of a peripheraledge of one or more of the plate members 162, 164, 166 extends beyond acorresponding peripheral edge of the inner frame member 160. Thus, inthe illustrated arrangement, an “armored” outward appearance isachieved, wherein the plate members 162, 164, 166 appear as protectivearmor supported by the smaller, inner frame member 160. In otherarrangements, however, a peripheral edge of inner frame member 160 mayextend beyond a corresponding peripheral edge of one or more of theplate members 162, 164, 166. Accordingly, in such an arrangement, theinner frame member 160 may have a larger frontal surface area than thecombination of plate members 162, 164, 166.

In the illustrated arrangement, the plate members 162, 164, 166 arefixedly secured to the forward-facing surface 160A of the inner framemember 160 by an ultrasonic welding process. In such a process, one orboth of the plate members 162, 164, 166 and the inner frame member 160,are subjected to ultrasonic vibrations. When the plate member and theinner frame member 160 are brought into contact with one another, theresulting vibratory energy is converted to heat, which melts and weldsthe plate member to the inner frame member 160. Such a process is knownin the art and, therefore, a further description is not deemed necessaryin order to practice the invention.

Although an ultrasonic welding process is preferred, the plate members162, 164, 166 may be secured to the inner frame member 160 by othersuitable processes or methods. For example, mechanical fasteners, suchas screws or rivets for example, may also be used. Alternatively,adhesives may be used to secure the plate members 162, 164, 166, to theinner frame member 160. In another arrangement, the plate members 162,164, 166 may be over-molded onto the inner frame member 160, similar tothe process described with reference to the eyeglass frames 20, 20′, ofFIGS. 1-10.

In a preferred arrangement, both the inner frame member 160 and theplate members 162, 164, 166 are constructed of a plastic material by asuitable process, such as injection molding, for example. That is, inone preferred arrangement, the inner frame member 160 and the platemembers 162, 164, 166 are constructed from the same, or a similarmaterial. In other arrangements, however, the inner frame member 160 andthe plate members 162, 164, 166 may be constructed of dissimilarmaterials. For example, the plate members 162, 164, 166 may beconstructed from a metal material (such as steel, aluminum, titanium, ormagnesium, for example), while the inner frame member 160 is constructedfrom a plastic material. Other combinations are also possible, as may beappreciated by one of skill in the art.

The earstems 158 may also include an inner frame member and one or moreouter plate members, similar to those described in relation to the frontportion 152 of the eyeglass frame 150. For example, a forward portion172 of the earstems 158 may comprise another plate member fixedlysecured to the remainder of the earstem 158, which serves as an innerframe member.

As described above, preferably the plate members 162, 164, 166 arefixedly secured to the inner frame member 160 by an ultrasonic weldingprocess. With reference to FIG. 20, a preferred arrangement forenhancing the ultrasonic welding process is illustrated. Desirably, anrearward-facing surface of the right lower plate member 166R, whichfaces the forward-facing surface 160A of the inner frame member 160,includes a pair of projections 180, extending in a rearward directionfrom the plate member 166R. A pair of corresponding roughened surfaceareas 182 are provided on the forward-facing surface 160A of the innerframe member 160 and are sized, shaped and spaced to align with theprojections 180.

In operation, the projections 180 function as energy directors duringthe ultrasonic welding process. The energy directors, or projections180, provide a reduced contact surface area between the plate member166R and the forward-facing surface 160A of the inner frame member 160.Such an arrangement focuses the energy into a small area to increase theheat generated and, thus, permit rapid melting of the projections 180 toform a welded joint between the plate member 166 and the inner framemember 160. The roughened surface areas 182 operate to retain theprojections 180 in a desired location, relative to the inner framemember 160, during the welding process.

With reference to FIG. 21, a preferred method 184 is illustrated in aprocess flow diagram for a construction of an eyeglass frame, such asthe eyeglass frame 150 of FIG. 11 through 20. In step 186, the innerframe member 160 of the front portion 152 of the eyeglass frame 150 isformed in a first mold. As described above, preferably the inner framemember 160 is formed from a plastic material by injection molding. Instep 188, the plate members 162, 164, 166 are formed in a second mold,or plurality of molds. Preferably, the plate members 162, 164, 166 arealso constructed of a plastic material by an injection molding process.

In step 190, the plates 162, 164, 166 are secured to the inner framemember 160, preferably by an ultrasonic welding process, as describedabove. However, other suitable methods of securing the plate members162, 164, 166 to the inner frame member 160 may also be used.

In step 192, the earstem 158 is formed in a first mold. Preferably, theearstem 158 is formed from a plastic material by an injection moldingprocess. Optionally, in step 194, an earstem plate member may be formedin a second mold. Preferably, the earstem plate member would also beconstructed of a plastic material by an injection molding process. Instep 196, if necessary, the earstem plate member would be secured to theearstem 158, preferably by an ultrasonic welding process.

In step 198, a pair of earstems, preferably each being formed by aprocess as described in relations to steps 192, 194, 196, are assembledto the front portion 152 to form a frame assembly 150. In step 200, apair of optical lenses (not shown) are assembled to the completed frameassembly 150, as is well known in the art. Although the above-describedprocess is preferred, other suitable processes for creating the eyeglassframe 150 may also be used.

In the above-described embodiments, two members of material are securedto one another to create an eyeglass frame to achieve a desiredaesthetic appearance. As such, preferably, a forward-facing surface ofeach of the members is visible when viewed from a forward side of theeyeglass frame. Thus, the first and second members preferably are atleast partially, but not entirely, coextensive. In addition, each of themembers are desirably “sculpted”. That is, preferably, each of themembers varies in either, or both, cross-sectional area andcross-sectional shape at various points along the members. In otherwords, desirably, each of the members contributes to the outwardappearance of the eyeglass frame and is not provided, at least entirely,for the purpose of strengthening the frame. Accordingly, in a preferredarrangement, neither member is of a consistent cross-sectional area, orshape, as opposed to a typical stiffening members, such as a stiffeningwire, for example.

Although the present invention has been described in relation topreferred embodiments, it is not intended to limit the present inventionto the embodiments disclosed. Modifications apparent to one of ordinaryskilled in the art may be made without departing from the true spiritand scope of the invention. Accordingly, the present invention isintended to be defined only by the appended claims.

1. An eyeglass frame, comprising: a frame body including a frame portionand first and second earstem portions, said frame portion defining firstand second orbitals, each of said orbitals configured to support anoptical lens, said earstem portions being spaced from one another andextending in a rearward direction from said front portion; wherein saidframe body comprises a first member and a second member, said firstmember and said second member being at least partially coextensive, andeach of said first and second members defining a portion of an outersurface of said frame body.
 2. The eyeglass frame of claim 1, whereinsaid first member defines a recess and said second member occupies saidrecess.
 3. The eyeglass frame of claim 1, wherein said second member ismechanically secured to said first member.
 4. The eyeglass frame ofclaim 1, wherein said second member is chemically secured to said firstmember.
 5. The eyeglass frame of claim 1, wherein said first memberextends over no more than about one-third of a total length of saidearstem portions.
 6. The eyeglass frame of claim 5, wherein said firstmember extends over about one-third of said total length of said earstemportions.
 7. The eyeglass frame according to claim 5, wherein the firstportion is formed of a metal material.
 8. The eyeglass frame accordingto claim 5, wherein the second portion is formed of a translucentmaterial.
 9. The eyeglass frame according to claim 5, wherein secondportion is formed from a transparent material.
 10. An eyeglass framecomprising a frame body including a frame portion and first and secondearstem portions, said frame portion defining at least one orbitalconfigured to support an optical lens, wherein said frame body comprisesa first layer and a second layer, said first layer and said second layerbeing at least partially coextensive, and means for affixing said firstlayer to said second layer such that each of said first and second layerdefine a portion of an outer surface of said frame body.
 11. An eyeglassframe, comprising: a plurality of plate-like members cooperating to forma discontinuous frame portion defining at least one orbital; a framemember sized and shaped to interconnect at least a portion of saidplurality of plate-like members; wherein said portion of said plate-likemembers are supported by said frame member.
 12. The eyeglass frame ofclaim 11, wherein said plurality of plate-like members are affixed to aforward-facing surface of said frame member.
 13. The eyeglass frame ofclaim 11, wherein said plurality of plate-like members and said framemember comprise a plastic material.
 14. The eyeglass frame of claim 11,wherein said plurality of plate-like members are a different color thansaid frame member.
 15. The eyeglass frame of claim 14, wherein saidframe member is substantially transparent.
 16. An eyeglass framecomprising a frame body defining first and second orbitals, each of saidfirst and second orbitals configured to support an optical lens, saidframe body comprising a first member and a second member, said firstmember defining a first shape and said second member defining a secondshape substantially similar to said first shape, and means for affixingsaid second member to said first member such that each of said first andsecond members define a portion of a forward-facing surface of saidframe body.
 17. The eyeglass frame of claim 16, wherein said secondmember comprises a plurality of individual plates.
 18. An eyeglassframe, comprising: a frame member defining an orbital; a plurality ofplate-like members cooperating to form a discontinuous frame portionsurrounding said orbital; wherein said plate-like members are supportedby said frame member.
 19. The eyeglass frame of claim 18, wherein saidsurface of said frame member is a forward facing surface.
 20. Theeyeglass frame of claim 18, wherein said plurality of plate-like memberssurrounding said orbital comprises at least three plate-like members.